Sport balls and method of manufacturing the sport balls

ABSTRACT

A sport ball includes a casing forming an exterior surface thereof. The casing has a plurality of joined panels forming a partially-assembled casing and defining an open area. A closure panel substantially fills the open area of the partially-assembled casing. A backing layer is radially inward of, and attached to, the closure panel. The backing layer extends beyond a peripheral boundary of the closure panel, such that the backing layer at least partially overlaps one or more of the joined panels adjacent to the open area of the partially-assembled casing. A bladder is radially inward of, and attached to, the closure panel. The bladder includes a valve for introducing fluid into the ball. The valve extends through the backing layer and the closure panel. A backing patch may be attached either to the closure or the partially-assembled casing, and overlaps a portion of both.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of application Ser. No. 14/589,466,filed Jan. 5, 2015, which was a divisional of application Ser. No.13/434,891 (now U.S. Pat. 8,926,459), filed Mar. 30, 2012, both of whichare hereby incorporated by reference in their entirety.

INTRODUCTION

A variety of inflatable sport balls, such as a soccer ball,conventionally exhibit a layered structure that includes a casing, anintermediate layer, and a bladder. The casing forms an exterior portionof the sport ball and is generally formed from a plurality of durableand wear-resistant panels joined together along abutting edges (e.g.,with stitching or adhesives). Although panel configurations may varysignificantly, the casing of a traditional soccer ball includesthirty-two panels, twelve of which have a pentagonal shape and twenty ofwhich have a hexagonal shape.

The intermediate layer forms a middle portion of the sport ball and ispositioned between the casing and the bladder. Among other purposes, theintermediate layer may provide a softened feel to the sport ball, impartenergy return, and restrict expansion of the bladder. In someconfigurations, the intermediate layer or portions of the intermediatelayer may be bonded, joined, or otherwise incorporated into the casingas a backing material.

The bladder, which has an inflatable configuration, is located withinthe intermediate layer to provide an interior portion of the sport ball.In order to facilitate inflation (i.e., with pressurized air), thebladder generally includes a valved opening that extends through each ofthe intermediate layer and casing, thereby being accessible from anexterior of the sport ball.

In order to facilitate joining of the panels that make up the casing,the casings of many balls are assembled inside-out, thus providingaccess to flanges at the edges of the panels that typically projectinward and are sewn, glued, or welded to flanges of adjacent panels.Once assembly of the inside-out casing is nearly complete, the casing isturned right-side-out, and the final unclosed portions of the casing arejoined to complete closure of the casing. For example, in some cases,one or two seams of a casing are left unclosed, providing an opening forthe casing to be turned right-side-out through. Once the casing isturned right-side-out, a bladder, restriction layer, and/or other layersmay be inserted through the opening before the last seams are joined,providing the final closure of the casing.

SUMMARY

A sport ball is provided. The sport ball includes a casing that forms anexterior surface of the sport ball. The casing has a plurality of joinedpanels forming a partially-assembled casing and defining an open areatherein. The casing also has a closure panel substantially filling theopen area of the partially-assembled casing.

A backing layer is attached to the closure panel, and is radially inwardof the closure panel. The backing layer extends beyond a peripheralboundary of the closure panel, such that the backing layer at leastpartially overlaps one or more of the joined panels adjacent to the openarea of the partially-assembled casing.

A bladder is attached to the closure panel. The bladder is radiallyinward of the backing layer and includes a valve for introducing fluidinto the ball. The valve extends through both the backing layer and theclosure panel.

A backing patch may be attached to either the closure or thepartially-assembled casing. The backing patch overlaps at least aportion of both the closure panel and the partially-assembled casing.

The above features and advantages, and other features and advantages, ofthe present subject matter are readily apparent from the followingdetailed description of some of the best modes and other embodiments forcarrying out the disclosed structures, methods, or both.

FIGURE DESCRIPTIONS

FIG. 1 is a perspective view of a sport ball.

FIG. 2 is another perspective view of the sport ball.

FIG. 3 is a cross-sectional view of a portion of the sport ball, asdefined by section line 3-3 in FIG. 2.

FIG. 4 is a top plan view of a panel of the sport ball.

FIG. 5 is a perspective view of two joined panels.

FIG. 6 is a cross-sectional view of the joined panels, as defined bysection line 6-6 in FIG. 5.

FIG. 7 is a perspective view of a welding tool utilized in joining thepanels.

FIG. 8 is a cross-sectional view of the welding tool, as defined bysection line 8-8 in FIG. 7.

FIGS. 9A-9E are schematic cross-sectional views depicting steps ofwelding the panels together in a manufacturing process for the sportball.

FIG. 10 is a cross-sectional view that corresponds with FIG. 8 anddepicts another configuration of the welding tool.

FIGS. 11A-11E are elevation views depicting further steps in themanufacturing process for a sport ball including installation of a finalcasing panel.

FIGS. 12A-12F are cross-sectional views of exemplary configurations offinal casing panels for a sport ball.

FIGS. 13A and 13B are cross-sectional views of the panels illustratingaspects of the process of installing the panels on a sport ball.

DETAILED DESCRIPTION

The following discussion and accompanying figures disclose various sportball configurations and methods relating to manufacturing of the sportballs. Although the sport ball is discussed and depicted in relation toa soccer ball, concepts associated with the configurations and methodsmay be applied to various types of inflatable sport balls. In additionto soccer balls, therefore, concepts discussed herein may beincorporated into basketballs, footballs (for either American footballor rugby), volleyballs, and water polo balls, for example. A variety ofnon-inflatable sport balls, such as baseballs and softballs, may alsoincorporate concepts discussed herein.

General Sport Ball Configuration

A sport ball 10 having the general configuration of a soccer ball isdepicted in FIGS. 1-3. Sport ball 10 exhibits a layered structure having(a) a casing 20 forms an exterior portion of sport ball 10, (b) anintermediate layer 30 located within casing 20, and (c) an inflatablebladder 40 that forms an interior portion of sport ball 10. Uponpressurization, bladder 40 induces sport ball 10 to take on asubstantially spherical shape. More particularly, pressure withinbladder 40 causes bladder 40 to place an outward force upon intermediatelayer 30. In turn, intermediate layer 30 places an outward force uponcasing 20. In order to limit expansion of bladder 40 and also limittension in casing 20, a portion of intermediate layer 30 may have alimited degree of stretch. In other words, bladder 40 places an outwardforce upon intermediate layer 30, but the stretch characteristics ofintermediate layer 30 effectively prevent the outward force frominducing significant tension in casing 20. Accordingly, intermediatelayer 30 restrains pressure from bladder 40, while permitting outwardforces to induce a spherical shape in casing 20, thereby imparting aspherical shape to sport ball 10.

Casing 20 is formed from various panels 21 that are joined togetheralong abutting sides or edges to form a plurality of seams 22. Althoughpanels 21 are depicted as having the shapes of twelve equilateralpentagons, panels 21 may have non-equilateral shapes, concave or convexedges, or a variety of other shapes (e.g., triangular, square,rectangular, hexagonal, trapezoidal, round, oval, non-geometrical) thatcombine in a tessellation-type manner to form casing 20. In someconfigurations, sport ball 10 may have twelve pentagonal panels 21 andtwenty hexagonal panels 21 to impart the general configuration of atraditional soccer ball. Selected panels 21 may also be formed ofunitary (i.e., one piece) construction with adjacent panels 21 to formbridged panels that reduce the number of seams 22. Accordingly, theconfiguration of casing 20 may vary significantly.

Panels 21 may be joined to form seams 22 in any suitable manner. Forexample, in some configurations, panels 21 may be joined with stitching(e.g., hand or machine stitching), in a conventional or alternativemanner. In some configurations, a welding process may be utilized in themanufacture of sport ball 10 to join panels 21 and form seams 22. Moreparticularly, panels 21 may be at least partially formed from a polymermaterial, which may be a thermoplastic polymer material, and edges ofpanels 21 may be heated and bonded to each other to form seams 22. Anexample of the configuration of seams 22 is depicted in thecross-section of FIG. 3, wherein the welding process has effectivelysecured, bonded, or otherwise joined two of panels 21 to each other bycombining or intermingling the polymer material from each of panels 21.In other configurations, some of panels 21 may be joined throughstitching, or various seams 22 may be supplemented with stitching.

One advantage of utilizing a welding process to form seams 22 relates tothe overall mass of sport ball 10. Whereas approximately ten to fifteenpercent of the mass of a conventional sport ball may be from the seamsbetween panels, welding panels 21 may reduce the mass at seams 22. Byeliminating stitched seams in casing 20, the mass that would otherwisebe imparted by the stitched seams may be utilized for other structuralelements that enhance the performance properties (e.g., energy return,sphericity, mass distribution, durability, aerodynamics) of sport ball10. Another advantage relates to manufacturing efficiency. Stitchingeach of the seams of a conventional sport ball is a relativelytime-consuming process, particularly when hand stitching is utilized. Bywelding panels 21 together at seams 22, the time necessary for formingcasing 20 may be deceased, thereby increasing the overall manufacturingefficiency.

Intermediate layer 30 is positioned between casing 20 and bladder 40 andmay be formed to include one or more of a compressible foam layer thatprovides a softened feel to the sport ball, a rubber layer that impartsenergy return, and a restriction layer to restrict expansion of bladder40. The overall structure of intermediate layer 30 may varysignificantly. As an example, the restriction layer may be formed from(a) a thread, yarn, or filament that is repeatedly wound around bladder40 in various directions to form a mesh that covers substantially all ofbladder 40, (b) a plurality of generally flat or planar textile elementsstitched together to form a structure that extends around bladder 40, or(c) a plurality of generally flat or planar textile strips that areimpregnated with latex and placed in an overlapping configuration aroundbladder 40 The restriction layer may also be a substantially seamlessspherically-shaped textile, as disclosed in Raynak et al.,

U.S. Patent Application Publication Number 2009/0325746, published Dec.31, 2009. In some configurations of sport ball 10, intermediate layer 30or portions of intermediate layer 30 may also be bonded, joined, orotherwise incorporated into casing 20 as a backing material, orintermediate layer 30 may be absent from sport ball 10. Accordingly, thestructure of intermediate layer 30 may vary significantly to include avariety of configurations and materials.

Bladder 40 has an inflatable configuration and is located withinintermediate layer 30 to provide an inner portion of sport ball 10. Wheninflated, bladder 40 exhibits a rounded or generally spherical shape. Inorder to facilitate inflation, bladder 40 may include a valved opening(not depicted) that extends through intermediate layer 30 and casing 20,thereby being accessible from an exterior of sport ball 10, or bladder40 may have a valveless structure that is semi-permanently inflated.Bladder 40 may be formed from a rubber or carbon latex material thatsubstantially prevents air or other fluids within bladder 40 fromdiffusing to the exterior of sport ball 10. In addition to rubber andcarbon latex, a variety of other elastomeric or otherwise stretchablematerials may be utilized for bladder 40. In some configurations,bladder 40 may also have a structure formed from a plurality of joinedpanels, as disclosed in Rapaport et al., U.S. Patent ApplicationPublication Number 2009/0325745 published Dec. 31, 2019.

Manufacturing Process

The panels of conventional sport balls, as discussed above, may bejoined with stitching (e.g., hand or machine stitching). Panels 21 are,however, at least partially formed from a polymer material, which may bea thermoplastic polymer material, that can be joined through the weldingprocess. Referring to FIG. 4, one of panels 21 prior to incorporationinto sport ball 10 is depicted as having a panel area 23 and five flangeareas 24. Whereas panel area 23 generally forms a central portion ofpanel 21, flange areas 24 generally form edge portions of panel 21 andextend around panel area 23. For purposes of reference, dashed lines aredepicted as extending between panel area 23 and the various flange areas24. Panel 21 has a pentagonal shape and each of flange areas 24correspond with one side region of the pentagonal shape. In furtherconfigurations where a panel has a different shape, the number of flangeareas may change to correspond with the number of sides of the shape.Panel 21 defines five notches 25 that extend inward from vertices of thepentagonal shape and effectively separate the various flange areas 24from each other. Notches 25 may, therefore, permit flange areas 24 toflex or otherwise move independent of each other, although flange areas24 remain connected to panel area 23. Additionally, each flange area 24defines various registration apertures 26 that form holes extendingthrough panel 21.

Panel areas 23 of the various panels 21 form a majority, or all of, theportion of casing 20 that is visible on the exterior of sport ball 10.Flange areas 24, however, form portions of panels 21 that are bondedtogether to join panels 21 to each other. Referring to FIGS. 5 and 6, anexample of the manner in which two panels 21 are joined to each other isdepicted. Although panel areas 23 are generally co-planar with eachother, the joined flange areas 24 bend upward and are joined alongabutting surfaces. Additionally, registration apertures 26 from each ofthe joined flange areas 24 are aligned. By aligning registrationapertures 26 prior to bonding (i.e., through welding), flange areas 24are properly positioned relative to each other. As discussed in greaterdetail below, portions of the joined flange areas 24 may be trimmedduring the manufacturing process for casing 20. Note that theupwardly-facing surfaces in FIGS. 5 and 6 are located on an interior ofsport ball 10 once manufacturing is completed, and downwardly-facingsurfaces form an exterior surface of sport ball 10.

Panels 21 are discussed above as including a polymer material, which maybe utilized to secure panels 21 to each other. Examples of suitablepolymer materials for panels 21 include thermoplastic and/or thermosetpolyurethane, polyamide, polyester, polypropylene, and polyolefin. Insome configurations, panels 21 may incorporate filaments or fibers thatreinforce or strengthen casing 20. In further configurations, panels 21may have a layered structure that includes an outer layer of the polymermaterial and an inner layer formed from a textile, polymer foam, orother material that is bonded with the polymer material. Panels 21 mayalso incorporate multiple joined layers formed from a variety ofmaterials.

When exposed to sufficient heat, the polymer materials within panels 21transition from a solid state to either a softened state or a liquidstate, particularly when a thermoplastic polymer material is utilized.When sufficiently cooled, the polymer materials then transition backfrom the softened state or the liquid state to the solid state. Basedupon these properties of polymer materials, welding processes may beutilized to form a weld that joins portions of panels 21 (i.e., flangeareas 24) to each other. As utilized herein, the term “welding” orvariants thereof is defined as a securing technique between two elementsthat involves a softening or melting of a polymer material within atleast one of the elements such that the materials of the elements aresecured to each other when cooled. Similarly, the term “weld” orvariants thereof is defined as the bond, link, or structure that joinstwo elements through a process that involves a softening or melting of apolymer material within at least one of the elements such that thematerials of the elements are secured to each other when cooled. Asexamples, welding may involve (a) the melting or softening of two panels21 that include polymer materials such that the polymer materials fromeach panel 21 intermingle with each other (e.g., diffuse across aboundary layer between the polymer materials) and are secured togetherwhen cooled and (b) the melting or softening a polymer material in afirst panel 21 such that the polymer material extends into orinfiltrates the structure of a second panel 21 (e.g., infiltratescrevices or cavities formed in the second panel 21 or extends around orbonds with filaments or fibers in the second panel 21) to secure thepanels 21 together when cooled. Welding may occur when only one panel 21includes a polymer material or when both panels 21 include polymermaterials. Additionally, welding does not generally involve the use ofstitching or adhesives, but involves directly bonding panels 21 to eachother with heat. In some situations, however, stitching or adhesives maybe utilized to supplement the weld or the joining of panels 21 throughwelding.

A variety of techniques may be utilized to weld flange areas 24 to eachother, including conduction heating, radiant heating, radio frequencyheating, ultrasonic heating, and laser heating. An example of a weldingdie 50 that may be utilized to form seams 22 by bonding two flange areas24 is depicted in FIGS. 7 and 8. Welding die 50 includes two portions 51that generally correspond in length with a length of one of the sides ofpanels 21. That is, the length of welding die 50 is generally as long asor longer than the lengths of flange areas 24. Each portion 51 alsodefines a facing surface 52 that faces the other portion 51. That is,facing surfaces 52 face each other. If utilized for purposes ofconduction heating, for example, portions 51 may each include internalheating elements or conduits that channel a heated liquid in order tosufficiently raise the temperature of welding die 50 to form a weldbetween flange areas 24. If utilized for purposes of radio frequencyheating, one or both of portions 51 may emit radio frequency energy thatheats the particular polymer material within panels 21. In addition towelding die 50, a variety of other apparatuses that may effectively forma weld between panels 21 may be utilized.

A general process for joining panels 21 with welding die 50 will now bediscussed with reference to FIGS. 9A-9E. Initially, adjacent flangeareas 24 from two panels 21 are located such that (a) surfaces of theflange areas 24 face each other and (b) registration apertures 26 aregenerally aligned, as depicted in FIG. 9A. Portions 51 of welding die 50are also located on opposite sides of the abutting flange areas 24.Portions 51 then compress flange areas 24 together between facingsurfaces 52 to cause surfaces of flange areas 24 to contact each other,as depicted in FIG. 9B. By heating flange areas 24 with welding die 50,the polymer materials within flange areas 24 melt or otherwise soften toa degree that facilitates welding between flange areas 24, as depictedin FIG. 9C, thereby forming seam 22 between panels 21. Once seam 22 isformed by bonding flange areas 24 together, portions 51 may retract fromflange areas 24, as depicted in FIG. 9D. Excess portions of flange areas24, which may include portions that define registration apertures 26,are then trimmed or otherwise removed to complete the formation of oneof seams 22, as depicted in FIG. 9E.

A variety of trimming processes may be utilized to remove the excessportions of flange areas 24. As examples, the trimming processes mayinclude the use of a cutting apparatus, a grinding wheel, or an etchingprocess. As another example, welding die 50 may incorporate cuttingedges 53, as depicted in FIG. 10, that trim flange areas 24 during thewelding process. That is, cutting edges 53 may be utilized to protrudethrough flange areas 24 and effectively trim flange areas 24 as portions51 heat and compress flange areas 24 together between facing surfaces52.

The general process of welding flange areas 24 to form seams 22 betweenpanels 21 was generally discussed above relative to FIGS. 9A-9E. Thisgeneral process may be repeatedly performed with multiple panels 21 andon multiple flange areas 24 of each panel 21 to effectively form agenerally spherical or substantially closed structure, as depicted inFIG. 11A. That is, multiple panels 21 may be welded together through thegeneral process discussed above in order to form various seams 22 incasing 20.

As shown in FIG. 11A, a method of making ball 10 may include forming apartially assembled casing 20 by joining a plurality of panels 21,leaving one open area 28 configured to receive a closure panel. Asfurther shown in FIG. 11A, the partially assembled casing 20 may beformed inside-out, as illustrated by flange areas 24 projecting radiallyoutward from the center of ball 10.

FIG. 11B depicts a similar configuration, wherein flange areas 24 havebeen trimmed. As discussed above, the trimming or removal of flangeareas 24 may occur following the stitching or welding process or mayoccur at the time of the stitching or welding process.

FIG. 11C illustrates an intermediate or backing layer 30 having beenplaced over at least a portion of the inside-out, partially assembledcasing. In this configuration, flange areas 24 may create bulges 31 inbacking layer 30. When the assembly is turned right-side-out, thesebulges will project inward. As further illustrated in FIG. 11C, theassembly method may also include locating an opening 32 in backing layer30 over open area 28 of the partially assembled casing 20.

Following placement of backing layer 30, casing 20 may be reversed orturned right-side-out through opening 32 and open area 28 to impart theconfiguration depicted in FIG. 11D. Whereas the trimmed portions offlange areas 24 protrude outward in FIG. 11B, reversing or turningcasing 20 right-side-out through opening 32 places all of flange areas24 within casing 20. Accordingly, the trimmed flange areas 24 protrudeinward, rather than outward, once casing 20 is reversed or turnedright-side-out. Referring to FIG. 3, for example, an exterior of casing20 has a generally smooth configuration, while portions of casing 20corresponding with flange areas 24 protrude inward. Panels 21 may formindentations on the exterior of sport ball 10 in the areas of seams 22.

As shown in FIG. 11D, opening 32 in backing layer 30 may be smaller thanopen area 28 of the partially assembled casing 20. Once the assembly ofcasing 20 and backing layer 30 is in the configuration shown in FIG.11D, a closure assembly 60 may be installed. Closure assembly 60 mayinclude a closure panel 61, which may have substantially the sameconfiguration as the rest of panels 21 that make up casing 20. Forexample, closure panel 61 and panels 21 may have the same orsubstantially the same layered structure. Closure assembly 60 may alsoinclude bladder 40, which may be attached to closure panel 61 andinserted through opening 32. As illustrated in FIG. 11D, bladder mayalso include a valve 62 for introducing fluid to bladder 40. In someconfigurations, valve 62 may extend through closure panel 61.

As can be seen from the view shown in FIG. 11D, backing layer 30provides a surface upon which closure panel 61 may be mounted in openarea 28, while still providing an opening 32 through which casing 20 maybe turned right-side-out. When serving as a backing layer 30, theintermediate layer may have the same or similar composition as describedabove. For example, in some configurations, backing layer 30 may have alimited amount of stretch. This may retain the spherical shape of theball, and may also provide a sturdy surface on which a closure panel maybe mounted.

To install closure assembly 60, bladder 40 may be inserted throughopening 32, and closure panel 61 may be attached to ball 10 in anysuitable manner. For example, in some configurations, installing closurepanel 61 may include attaching closure panel 61 to backing layer 30 withadhesive. In some configurations, installing closure panel 61 mayattaching closure panel 61 to panels 21 adjacent to closure panel 61 bywelding.

FIG. 11E illustrates ball 10 with closure assembly 60, including closurepanel 61 installed. As part of the closure process, closure seams 63 maybe formed, for example, as welds.

Exemplary Closure Assembly Configurations

FIG. 12A is an enlarged cross-sectional view of closure assembly 60 asit is being installed in ball 10. As shown in FIG. 12A, backing layer 30may be located radially inward of closure panel 61. Backing layer 30 mayextend beyond a peripheral boundary of closure panel 61 and may leastpartially overlap with one or more panels 21 adjacent to closure panel61. Further, backing layer 30 may include opening 32, which may belocated radially inward of closure panel 61. As shown in FIG. 12A,opening 32 may be smaller than the surface area of closure panel 61,thus providing a backing portion 33 upon which closure panel 61 may bemounted.

In some configurations, the peripheral edges of closure panel 61 may berounded slightly, as shown in FIG. 12A. This rounded configuration mayprovide the appearance of a seam when closure panel 61 is installed. Forexample, even if closure panel 61 is installed using adhesive, theresulting boundary between closure panel 61 and adjacent panels 21 willappear similar to the seams 22 between panels 21, which may be formed bywelding and/or stitching.

In some configurations, casing 20 may include multiple layers. Forexample, as shown in FIG. 12A, casing 20 may include an outer layer 121,a middle layer 122, and an inner layer 123. In some configurations,inner layer 123 may be separate from backing layer 130, as shown in FIG.12A.

As also shown in FIG. 12A, bladder 40 may be inserted through opening 32during the installation of closure assembly 60. Further, bladder 40 mayinclude valve 62, which extends through opening 32 and through casing 20of closure panel 61. Once fully installed, bladder 40 may be locatedradially inward of backing layer 30.

In some configurations, backing layer 30 may line the entire innersurface of casing 20 except for the area where opening 32 is located.Although truncated for purposes of illustration, FIG. 12A shows thisconfiguration where backing layer 30 is a substantially complete liningof casing 20.

FIG. 12B illustrates an alternative configuration of closure assembly60. As shown in FIG. 12B, in some configurations, inner layer 123 ofcasing 20 may extend to form backing portion 33. In some configurations,inner layer 123 may serve as the backing layer by itself. In otherconfigurations, inner layer 123 may be accompanied by an additionalbacking layer 30, which may serve as an intermediate layer betweenbladder 40 and casing 20, as shown in FIG. 12B.

As also shown in FIG. 12B, peripheral portions 64 of closure panel 61may have any of various shaped configurations. Not only may peripheralportions 64 be tapered, in order to provide the appearance of a seam, asdiscussed above, but also, peripheral portions 64 may be configured tomate with edge portions of adjacent panels 21. For example, in someconfigurations, peripheral portions 64 may overlap with edge portions ofpanels 21. Such a configuration may facilitate a welding closureprocess. Further, such a configuration may also provide for a moresealed seam for both welded and stitched closures.

As further shown in FIG. 12B, in some configurations, a piece ofmaterial may be attached to the inside of closure panel 61 that is thesame material as backing layer 30. Such a piece of material may have asize and shape configured to substantially fill opening 32 in backinglayer 30.

FIG. 12C illustrates another configuration. For example, as shown inFIG. 12C, in some configurations, backing portion 33 may be providedonly by backing layer 30, and peripheral portions 64 of closure panel 61may be shaped, for example in an overlapping manner with adjacent panels21.

FIG. 12D illustrates yet another configuration. As shown in FIG. 12D, insome configurations, both bladder 40 and an intermediate layer 30 may beattached to closure panel 61. In addition, as further shown in FIG. 12D,a backing patch 70 may be included to provide backing portion 33 forattachment of closure panel 61. Thus, in this configuration, backingpatch 70 serves as the backing layer and may extend over only a portionof the inner surface of casing 20. An advantage of this configuration isthat backing patch 70 may be joined to the inner surface of casing 20after turning casing right-side-out through open area 28.

FIGS. 12E and 12F illustrates another ball configuration includingbacking patch 70. As shown in FIGS. 12E and 12F, in some configurations,backing patch 70 may be affixed to closure panel 61 to form closureassembly 60. Subsequently, packing patch 70 may be attached to innersurface 124 of inner layer 123 of casing 20. Closure panel 61 may befolded slightly in order to insert the extending portions of backingpatch 70 into opening 32. The extending portions of backing patch 70 maybe pressed against inner surface 124 of inner layer 123 of casing 20,for example, by inflating bladder 40, thereby pressing backing layer 30radially outward, as indicated by arrows in FIG. 12F. Backing patch 70may be secured to closure panel 61 and casing 20 by any suitablemechanism, such as adhesive.

As shown in FIG. 13A, in some configurations, closure panel 61 may beattached to backing layer 30 with adhesive. FIG. 13A illustrates anadhesive applicator 80, applying adhesive to a backing surface 34 inbacking portion 33 of backing layer 30.

As an alternative, or in addition to, adhesive, welding may be used toinstall closure panel 61. FIG. 13B illustrates an installed closureassembly 61. To the left in FIG. 13B, an adhesively bound joint 65 isdepicted. To the right in FIG. 13B, a welded joint 66 is depicted. Asfurther shown in FIG. 13B, a sealing die 90 may be used to create theweld in order to form welded joint 66.

The invention is disclosed above and in the accompanying figures withreference to a variety of configurations. The purpose served by thedisclosure, however, is to provide an example of the various featuresand concepts related to the invention, not to limit the scope of theinvention. Further, any of the features of any of the disclosedconfigurations may be used with any other disclosed configurations. Oneskilled in the relevant art will recognize that numerous variations andmodifications may be made to the configurations described above withoutdeparting from the scope of the present invention, as defined by theappended claims.

The detailed description and the drawings or figures are supportive anddescriptive of the subject matter discussed herein. While some of thebest modes and other embodiments for have been described in detail,various alternative designs, configurations, and embodiments exist.

1. A sport ball comprising: a casing that forms an exterior surface ofthe sport ball, the casing including: a plurality of joined panelsforming a partially-assembled casing and defining an open area therein,and a closure panel substantially filling the open area of thepartially-assembled casing; a backing layer attached to the closurepanel, wherein the backing layer is radially inward of the closure paneland extends beyond a peripheral boundary of the closure panel, such thatthe backing layer at least partially overlaps one or more joined panelsadjacent to the open area of the partially-assembled casing; and abladder attached to the closure panel, wherein the bladder is radiallyinward of the backing layer and includes a valve for introducing fluidinto the ball, the valve extending through the backing layer and theclosure panel.
 2. The sport ball of claim 1, further comprising: abacking patch attached to one of the closure panel and thepartially-assembled casing, wherein the backing patch overlaps at leasta portion of both the closure panel and the partially-assembled casing.3. The sport ball of claim 1, wherein the casing includes an innersurface and wherein the backing layer contacts substantially the entireinner surface of the casing.
 4. The sport ball of claim 1, wherein theclosure panel is attached to the panels adjacent to the closure panel byone or more welds.
 5. The sport ball of claim 2, wherein the backinglayer contacts substantially an entire inner surface of the casing.
 6. Asport ball comprising: a casing having an inner surface and an outersurface, the outer surface forming an exterior surface of the sportball, wherein the casing includes: a partially-assembled casing formedby a plurality of joined panels, wherein an open area is defined in thepartially-assembled casing, and a closure panel substantially fillingthe open area of the partially-assembled casing; a backing layer locatedradially inward of the closure panel and attached to the closure panel,wherein the backing layer extends beyond a peripheral boundary of theclosure panel and at least partially overlaps one or more of the joinedpanels of the partially-assembled casing, wherein the backing layerlines substantially the entire inner surface of the casing.
 7. The sportball of claim 6, further comprising: a backing patch attached to thepartially-assembled casing, wherein the backing patch overlaps at leasta portion of the closure panel.
 8. The sport ball of claim 7, whereinthe backing layer includes an opening located radially inward of theclosure panel, the opening being smaller than the surface area of theclosure panel, and further comprising: a bladder located radially inwardof the closure panel and attached to the closure panel, wherein thebladder includes a valve for introducing fluid into the ball, the valveextending through the opening in the backing layer and the closurepanel.
 9. The sport ball of claim 8, wherein the closure panel isattached to the joined panels of the partially-assembled casing by oneor more welds.
 10. The sport ball of claim 6, further comprising: abacking patch attached to the closure panel, wherein the backing patchoverlaps at least a portion of the partially-assembled casing.
 11. Thesport ball of claim 10, wherein the backing layer includes an openinglocated radially inward of the closure panel, the opening being smallerthan the surface area of the closure panel, and further comprising: abladder located radially inward of the closure panel and attached to theclosure panel, wherein the bladder includes a valve for introducingfluid into the ball, the valve extending through the opening in thebacking layer and the closure panel.